Process for preparing high polymer latices from organic solvent dispersions

ABSTRACT

This process relates to the preparation of stable aqueous latices from solvent dispersions of elastomers and other high polymer compositions. The process in common with that of earlier applications is characterized, inter alia, by the establishment of a flow of gas comprising steam as a continuous phase into which an emulsion of a cement of the polymer is dispersed as an aerosol of latex droplets in a solvent-vapor continuum, followed by coalescence of the latex droplets and separation of the resulting coalesced liquid phase from the resulting solvent-vapor phase. 
     In the present disclosure, special provisions are made for generating from recovered water saturated with solvent (and possibly contaminated with carry-over of macromolecular material and/or emulsifier and/or latex droplets) the gas comprising steam employed in forming the initial continuous phase. By this process it is possible to essentially exclude or eliminate the continuous supply of external steam to the process and the disposal of the condensate resulting therefrom. In the preferred practice of these provisions the quantity of water supplied to the process thus can be reduced essentially to only that quantity of water constituting the aqueous phase of the latex product withdrawn from the process, and environmental pollution with process effluent liquid and solid materials may be avoided or greatly minimized. 
     Furthermore, in preferred embodiments the process utilizes material carried over in or with the vapors and inhibits process solid and solvent losses and thus increases the efficiency of the process.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of application Ser. No.226,419, filed Feb. 15, 1972, now U.S. Pat. No. 3,879,327, as acontinuation-in-part of my application Ser. No. 817,494, filed Apr. 18,1969, (now abandoned), which was an improvement over andcontinuation-in-part of my applications (a) Ser. No. 621,997, filed Mar.7, 1967 (now U.S. Pat. No. 3,503,917, issued Mar. 31, 1970), (b) Ser.No. 691,823, filed Dec. 16, 1967, now abandoned, (replaced byapplication Ser. No. 70,949, filed Sept. 10, 1970, now U.S. Pat. No.3,652,482, issued Mar. 28, 1972), (c) Ser. No. 767,790 filed Oct. 15,1968, (now U.S. Pat. No. 3,622,127, issued Nov. 23, 1971), and (d) Ser.No. 784,596, filed Dec. 18, 1968, (now U.S. Pat. No. 3,644,263, issuedFeb. 12, 1972), the disclosures of all of which are herein included byreference.

BACKGROUND OF THE INVENTION

1. Field of the Invention:

This invention like those of my aforesaid copending applications relatesto the production of high solids content aqueous latices with reducedpolymer losses by a process which reduces solvent losses, conserveswater and minimizes plant effluents thus reducing or eliminating wastematerial, and aims generally to provide improved method and apparatuscombinations therefor.

The processes of the aforesaid applications, with respect to which theinventions of the present application are improvements, have solved anumber of the problems of the prior art, by combinations of steps inwhich an aqueous dispersion of polymer cement is dispersed into a flowof steam or gas comprising steam, but in so doing consederablequantities of solvent and of water saturated with solvent and, incertain instances, of carried-over macromolecular substances have beenlost.

2. Description of the Prior Art:

In the earlier prior art, synthetic latices of macromolecular materialincluding elastomers and other high polymers were usually those preparedby emulsion polymerization, which can directly yield latices of uniformcolloidal particle size. In contrast high polymers made by essentiallyanhydrous catalyst polymerizations must be converted into latex. In thislatter case it has been proposed to prepare aqueous latices of highpolymers from solvent solutions thereof by processes of the type whichcomprise the general steps of (1) providing a dispersion or cement ofthe polymer in a volatile organic solvent for the polymer, (2) adding tosuch dispersion water and an aqueous emulsifier therefor and emulsifyingthe same to produce an emulsion, (3) stripping the volatile organicsolvent from the said emulsion, and (4) recovering the resulting latexproduct. However, in the practical art difficulty has been experiencedin attempting to render such proposed processes commercially feasible,inter alis, in that the stripping of solvent from the aqueous emulsionof polymer cement has resulted in losses of valuable materials. Theselosses have included (a) losses of polymer, (b) losses of solvent and(c) losses of water contaminated with solvent.

SUMMARY OF THE INVENTION

The particular improvements distinguishing the present invention fromthose of my aforesaid copending applications may be employed inpracticing any of the several embodiments of process and apparatus setforth in said applications.

In the present process the organic solvent cement of macromolecularsubstance as an emulsion in water is dispersed into a flow of steam andthe solvent is steam stripped from the emulsion resulting in latex andvapor, and on separating and condensing said vapor there is obtainedliquid solvent which may contain some water, and liquid water containingdissolved solvent. As heretofore stated said solvent and/or water maycontain polymer and emulsifier carried over from the separation, and assaid water contains dissolved solvent and in certain instancesemulsifier and solid polymer it is useless as boiler feed water andtherefore is generally passed to waste. The present process renders suchcontaminated water useful as process water, also, recovers from suchwater any solvent, polymer and emulsifier present therein and recyclessame to the process, thus improving the processing economics.

In more detail, in a first embodiment of the invention a latex isprepared from an organic solvent dispersion of a composition of anorganic solvent soluble or dispersible, water insoluble macromolecularsubstance by a process of the type which comprises: (1) providing adispersion of the said composition in essentially water-immisciblevolatile solvent which itself or as an azeotrope with water has aboiling point lower than that of water at atmospheric pressure, (2)adding water and emulsifier to said dispersion in proportions to form anemulsion having water as its continuum and emulsifying the same so thatthe discontinuous phase thereof is in particles at least principally ofprecursor latex particle size, (3) stripping the solvent from theemulsion to form a latex, and (4) recovering the latex product, andwhich comprises the particular steps of: (5) providing a moving flow ofgas comprising steam as an initial continuous phase, (6) dispersing thesaid emulsion into the flow of gas comprising steam as the initialcontinuous phase while subjecting the phases to a decrease of pressureand maintaining the temperature thereof below the limiting temperaturefor stability of the emulsion of particles of precursor latex particlesize, thereby vaporizing solvent from the dispersed droplets and forminglatex and vapors, (7) establishing a separating zone maintained at alower pressure, and establishing a flow of latex and vapor into saidseparating zone, (8) introducing into said separating zone the latexdroplets and vapor produced by step (6) and impinging said droplets uponthe flow of latex therein, (9) withdrawing from said separating zonevapors therein resulting from steps 7 and 8, and (10) withdrawing latexfrom said separating zone, and this process is improved by combining inthe process the further steps of: (11) cooling and condensing the vaporswithdrawn in step (9) to form a mixture comprising (a) said solvent inliquid form and (b) water containing said solvent; (12) effectingseparation of the liquid solvent (a) from said solvent-containing water(b); (13) vaporizing a quantity of said solvent-containing water (b)sufficient to form at least a substantial part of the flow of gascomprising steam required by step (5); and (14) providing the flow ofgas in step (5) at least in substantial part from the flow of gas formedin step (13).

In a particular species of said first embodiment step (13) thereof iseffected in a vaporizer in which there may accumulate any of saidmacromolecular substance which may be entrained in the vapors withdrawnin step (9), and the improvement further comprises the cooperating stepsof (15) isolating said vaporizer from the process from time to time, and(16) removing from said isolated vaporizer any macromolecular substanceaccumulated therein by circulating therethrough liquid solvent separatedin step (12).

In a preferred species of said first embodiment step (13) is effectedselectively in one of two vaporizers in which there may accumulate anyof said macromolecular substance and emulsifier that may be entrained inthe vapors withdrawn in step (9) and the improvement further comprisesthe steps of (15) from time to time using alternately the respectiveones of said vaporizers in step (13) while isolating from the processthe vaporizer not being so used, and (16) circulating through theisolated vaporizer liquid solvent separated in step (12) for removingtherefrom any macromolecular substance accumulated therein.

In yet another species of the first embodiment the latex withdrawn instep (10) is concentrated by vaporization of water therefrom, and the sovaporized water is at least in part condensed and combined with thesolvent-containing water (b) separated in step (12).

In a second embodiment of the invention steps (1) to (6) and (9) to (14)may be the same as in the first embodiment and steps (7) and (8) mayinvolve only (7) establishing a separating zone maintained at said lowerpressure and (8) introducing into said separating zone the latexdroplets and vapors produced by step (6), and in this embodiment alsothe cooperating steps (15) or (15) (16) referred to above may berespectively incorporated to obtain the advantages thereof.

Thus, objects of the invention, severally and interdependently, are toprovide new apparatus features and new combinations of steps, whichcontribute to produce an improved process. Other objects an advantagesof the invention will be apparent from the above general description andthe following more particular descriptions of preferred embodimentsthereof, which, however, are illustrative but not restrictive of theinvention, the scope of which is more particularly pointed out in theappended claims.

By the term "latex" as used herein is meant an aqueous suspension ofessentially colloidal polymer, i. e. macromolecular and/or low molecularweight particles and emulsifier material and the polymer componentsthereof may be selected from the following types and combinationsthereof:

i. homopolymer,

ii. interpolymer including block and graft polymer,

iii. hydrocarbon polymer,

iv. polar polymer,

v. polymer composition comprising polymer material selected from (i)through (iv) above and compounding ingredients including resins,synthetic resins and reinforcing fillers and/or non-reinforcing fillers.

By the term "colloidal particle" or "colloid" as used herein is meantparticles in the size range of 500 A to 10,000 A diameter, and by theterm upper portion of the colloidal size range is meant particles in thesize range of above 2,000 A, preferably 3,000 to 5,000 A, diameter.

By the term "precursor latex particle size" is meant a particle ofpolymer composition and solvent of such a size that when relieved of itssolvent content the resulting particle is a colloidal particle as abovedefined.

By the term "greater than precursor latex particle size" is meant aparticle of polymer composition and solvent which when relieved of itssolvent yields particles of greater than colloidal size, which reducethe mechanical stability of the latex. Such particles are usually from10 to 1,000 times as large as particles of precursor latex particlesize.

By the term "resin" as used herein is meant natural or synthetic resinthose inflammable amorphous vegetable products of secretion ordisintegration usually formed in special cavities of plants and suchresins are generally insoluble in water and soluble in alcohol, fusibleand of conchoidal fracture and are usually oxidation or polymerizationproducts of terpenes.

By the term "synthetic resin" as used herein is meant organic oxidation,polymerization or condensation products not produced in nature butproduced synthetically and having resin-like properties and which termdoes not include the synthetic rubbers. Synthetic resins include (1) theresinous polymers produced from unsaturated petroleum compounds byoxidation and/or polymerization such as resinous alpha-olefin polymers,(2) condensation resins such as the phenolic resins, the aminoplastresins, alkyd resins, glycerol-phthalate resins and the like; (3) thenon-rubber-like resinous polymers produced by cyclizing, hydrogenatingor halogenating unsaturated rubber-polymers such as cyclizedpolyisoprene, chlorinated polyisoprene and the like, (4) resins derivedfrom coal tar chemicals such as the cumarone-indene resins; (5) resinousmaterials prepared from vinyl, vinylidene and vinylene monomers; (6)resinous copolymers prepared from vinyl, vinylidene and vinylenemonomers with conjugated diene monomers such as the highstyrene-butadiene resins; (7) resinous copolymers prepared from vinyl,vinylidene, and vinylene monomers and alpha-olifins such as theethylene-vinyl acetate copolymers. As used herein the terms "syntheticresins" is restricted to those synthetic resins which are soluble in atleast one solvent essentially water immiscible and which itself or asits azeotrope with water has a boiling point lower than that of water atatmospheric pressure.

By the term "water-immiscible solvent" as used herein is meant anorganic solvent or solvent mixture which is essentially immiscible withwater in liquid phase, and which (a) has a boiling point less than theboiling point of water at atmospheric pressure, or which (b) forms anazeotrope with water which has a boiling point less than the boilingpoint of water at atmospheric pressure. Such water immiscible solventsinclude, but are not limited to, aliphatic, alicyclic, and aromatichydrocarbon solvents, especially those containing from 4 to 9 carbonatoms; the halo-carbon and halo-hydrocarbon solvents; and suitable polarsolvents, especially those containing oxygen. Examples of such solvents,all of which are of the class of physical solvents, are butane, pentane,hexane, cyclohexane, heptane, benzene, toluene, the xylenes, ethylbenzene, cumene, carbon tetrachloride, trichlorethylene, certain freons,and the like.

THE POLYMER MATERIAL (1)

The new process is applicable to the preparation of latices from solventsolutions or dispersions of polymer materials which are essentiallysolvent soluble or dispersible and essentially water insoluble,including natural rubber and polymers of ethylenically unsaturatedmonomer material containing from 2 to 20 carbon atoms, preferably from 2to 10 carbon atoms. It is especially applicable to those elastomers andplastomers which, with or without plasticizer, have the foregoingproperties and properties adapting their latices for use as adhesives,binders, film forming materials, coating materials, etc. Examples ofsuch elastomers and plastomers, illustrative but not restrictive ofthose to which the invention can be applied, are as follows: butylrubber, chlorinated butyl rubber, polyisobutylene, polybutadiene,polyisoprene, polyethylene, polypropylene (including both amorphousand/or crystalline polypropylene), ethylene-propylene polymer,ethylene-propylene-diene terpolymer, ethylene-vinylidene monomerinterpolymers (including ethylene-vinyl acetate copolymers),butadiene-ethylene copolymers, propylene-butene-1 copolymers,butadiene-styrene copolymer, nitrile rubber (includingbutadiene-acrylonitrile and butadiene-methacrylonitrile copolymers),natural rubber, hydrocarbon resins, any of the foregoing polymersgrafted with polar or other polymer grafts, as for example, those setforth in British Pat. No. 878,150 to Burke, published Sept. 27, 1961,and solvent soluble mixed plastomers and elastomers, e. g.butadiene-styrene-terpolymers with styrene copolymer resins includinggraft polymers thereof, as for example, those set forth in Hayes U.S.Pat. No. 2,802,808. Particularly included are those polymers which areprepared in essentially water immiscible orgaic liquid, or underessentially anhydrous conditions, from unsaturated monomers having 2 to20 carbon atoms.

COMPOUNDING INGREDIENTS (3) (3A)

The compounding ingredients which are especially contemplated in thepresent invention are the solid, particulate, compounding ingredientswhich are insoluble in the solvents (6), namely: fillers, includingrubber reinforcing fillers, pigments, etc., which by the presentinvention may be incorporated into the polymer composition particles ofthe latices, rather than merely in the water phases thereof. The solidparticulate compounding ingredients of this class comprise those setforth on pages 278 to 345of "Compounding Ingredients for Rubber" 3rdEdition (1961) published by Rubber World, New York, N.Y., hereinincorporated by reference, and on pages 146 to 217 of "BritishCompounding Ingredients for Rubber" by Brian J. Wilson (1958) publishedby W. Heffer and Sons, Ltd., Cambridge, England, herein incorporated byreference. These ingredients thus include but are not limited to carbonblack, talc, mica, lithopone, aluminum silicate, calcium silicate,silica, calcium carbonate, calcium sulfate, asbestos, organic pigments,inorganic pigments, and insoluble organic fillers including vinylicfillers and vinylic pigments. The insoluble organic fillers aredescribed in British Patent No. 799,043 to Burke published July 30, 1958and in chapter 15 entitled "Reinforcement of Rubber by Organic Fillers"in the treatise "Reinforcement of Elastomers" edited by Gerard Kraus(1965) published by International Publishers, New York, N.Y., hereinincorporated by reference.

D. THE EMULSIFIERS (8)

The invention in its broader aspects is not dependent on the use of anyparticular emulsifier or combination of emulsifiers, and may bepracticed with any selected emulsifier or emulsifier combinationsuitable for aqueously emulsifying the non-aqueous solvent solutions ordispersions of the polymer materials concerned, and/or for stabilizingthe latices derived therefrom in the aerosol generator, or forsubsequent treatment or conditioning, for which purpose the emulsifieror combination of emulsifiers must be water soluble or waterdispersible. Emulsifiers capable of forming stable aqueous emulsionswith polymers may be selected from the following sub-groups:

a. One or more anionic emulsifiers.

b. One or more cationic emulsifiers.

c. One or more nonionic emulsifiers.

d. Combinations of anionic and nonionic emulsifiers.

e. Combinations of cationic and nonionic emulsifiers.

The anionic, cationic and nonionic emulsifiers which are water solubleusually contain from 8 to 22 carbon atoms, when non-polymeric, but suchlimitation does not apply to those which are polymeric, where watersolubility or dispersability is the criterion. The polymeric emulsifiersare best employed in conjunction with non-polymeric emulsifiers.

Emulsifiers of the anionic, cationic, and nonionic types including insome instances those in polymeric forms are set forth in "Detergents andEmulsifiers 1973 Annual" by John W. McCutcheon, published by John W.McCutcheon, Inc., Morristown, N.J., and especially those listed thereinunder the headings of emulsifiers suitable for emulsion polymerizationor suitable for the emulsification of polymer material, or suitable forthe emulsification of hydrocarbons including hydrocarbon waxes, may beused in practicing the present invention. The use of about 5-20 percentby weight of emulsifier material based on the polymer compositioncontent of the polymer-solvent cement in practically all instancessuffices, and in most instances 5 to 6 or less percent by weight ofemulsifier based on polymer composition content of the cement issufficient, because the present process minimizes the amount ofemulsifier required.

The anionic emulsifiers include but are not limited to emulsifiers whichare alkali metal salts of fatty acids, partially hydrogenated fattyacids, rosin acids, disproportionated rosin acids, alkyl sulfates, aryland alkaryl sulfonates, and water soluble and dispersable emulsifiershaving the general formula: R(OCH₂ CH₂)_(n) OSO₃ X wherein R is analiphatic, aryl, alkaryl or cyclic radical, n is 1 to 9, and X is amonovalent alkali metal or ammonium radical.

Typical anionic emulsifiers are set forth in Table A.

                  TABLE A                                                         ______________________________________                                        Typical Anionic Emulsifiers                                                              Acid or                                                            Salt       Acid Radical    Trade Name                                         ______________________________________                                         1.  Potassium hydroabietic and                                                                              Dresinate 731                                                 dehydroabietic                                                  2.  Potassium disproportionated                                                                             Indusoil JC-11B                                               tall oil rosin                                                  3.  Sodium    hydrogenated    Armeen HT                                                     tallow fatty                                                                  acids                                                           4.  Sodium    lauryl sulfate  Sipex UB                                                                      Dupanol WAQ                                     5.  Sodium    tallow sulfate  Conco Sulfate T                                 6.  Ammonium  mononaphthalene Lomar PWA                                                     sulfonic acid                                                   7.  Sodium    dodecylbenzene  Santomerse 85B                                                sulfate                                                         8.  Sodium    polymerized alkyl                                                                             Daxad 15                                                      naphthalene     Daxad 23                                                      sulfonic acid                                                   9.  Sodium    alkyl aryl      Nacconol 90F                                                  sulfonate       Suframin OBS                                   10.  Sodium    alkylnaphthalene                                                                              Nekal BA-75                                                   sulfonate                                                      11.  Sodium    N-cyclohexyl-N- Igepon CN-42                                                  palmitoyl-taurate                                              12.  Sodium    lauryl ether    Sipon ES                                                      sulfate                                                        13.  Sodium    alkylaryl       Triton W-30                                                   polyether sulfate                                              14.  Sodium    sulfate ester of                                                                              Alipal CO-433                                                 nonylphenoxypoly                                                              (ethyleneoxy)                                                                 ethanol                                                        15.  Ammonium  sulfate ester of                                                                              Alipal CO-436                                                 nonylphenoxypoly                                                              (ethyleneoxy)                                                                 ethanol                                                        16.  Sodium    naphthalene     Nacconol NRSF                                                 sulfonic acid                                                  17.  Sodium    dioctyl ester of                                                                              Aerosol OT                                                    sulfosuccinic acid                                             18.  Sodium    saponified      Gantex AN-139                                                 poly(methylvinylether/                                                        maleic anhydride)                                              19.  Sodium    saponified poly-                                                                              Lytron                                                        (styrene/maleic SMA-3000A                                                     anhydride)                                                     ______________________________________                                    

The cationic emulsifiers include, but are not limited to, the class ofemulsifiers which are acid salts of primary, secondary, and tertiaryamines and the quaternary ammonium type emulsifiers. Typical cationicemulsifiers (used with acids to form water soluble salts when notquaternary ammonium compounds) are set forth in Table B.

                  TABLE B                                                         ______________________________________                                        Typical Cationic Emulsifiers                                                  Emulsifier Base       Trade Name                                              ______________________________________                                         1.  Cocoamine            Armeen C                                             2.  Stearylamine         Armeen T                                             3.  N-alkyl trimethylene diamines                                                                      Duomeen C                                                (alkyl groups derived from                                                                         Duomeen T                                                cocoanut, soya, and tallow                                                    fatty acids)                                                              4.  Primary fatty amine ethylene                                                                       Priminox T-25                                            oxide reaction products, e.g.                                                 RNH(CH.sub.2 CH.sub.2 O).sub.25 H                                         5.  Polyoxyethylated alkylamine                                                                        Katapol PN-430                                       6.  Ethylene oxide condensates                                                                         Ethomeens                                                with primary fatty amines                                                 7.  bis(2-hydroxyethyl)cocoamine                                                                       Armox C/12W                                              oxide                                                                     8.  bis(2-hydroxyethyl)tallow amine                                                                    Armox T/12                                               oxide                                                                     9.  Amine and quaternary ammonium                                                                      Redicote Series e.g.                                     compounds suitable as asphalt                                                                      Redicote E-4, E-5,                                       emulsifiers          E-9, E-12 and E-N.                                  10.  C.sub.18 H.sub.37 N(CH.sub.3).sub.2 ClC.sub.3 H.sub.6 N(CH.sub.3).sub         .3 Cl                Redicote E-11                                       11.  di-isobutyl phenoxy ethoxy                                                                         Hyamine 1622                                             ethyl dimethyl ammonium chloride                                         12.  N-alkyl trimethylammonium                                                                          Arquads                                                  chloride (alkyl = coco or steryl                                              radical)                                                                 13.  polyvinylpyrrolidone PVP                                                 ______________________________________                                    

Non-ionic emulsifiers can be selected from the class of emulsifierswhich are alkyl polyoxyethylene ethers and alcohols, or polyethyleneethers and alcohols. Other non-ionic emulsifiers include those which arepolyoxyalkenated alkyl phenols or alcohols having the formula R(OCHR₁CHR₁)_(n) OH where R is an alkyl, aryl or alkaryl group, R₁ is an alkylgroup or hydrogen and n is an integer of 4 to 10 or even higher.Compounds of this type are prepared by condensing an alkyl phenol or analcohol with ethylene oxide or propylene oxide. Typical nonionicemulsifiers are set forth in Table C.

                  TABLE C                                                         ______________________________________                                        Typical nonionic Emulsifiers                                                  Chemical Name         Trade Name                                              ______________________________________                                         1.  Nonylphenoxypoly(ethyleneoxy)-                                                                     Igepal CO-970                                            ethanol                                                                   2.  nonylphenyl polyethylene glycol                                                                    Tergitol TP-9                                            ether                                                                     3.  polyethyleneglycol fatty ester                                                                     Modecol L.                                           4.  coconut alkanolamide Monamine AA-100                                      5.  polyethyleneglycol 400                                                                             Pegmol-5942                                              monolaurate                                                               6.  propyleneglycol monolaurate                                                                          --                                                 7.  castordiethanolamide Emid-6547                                            8.  ethylene oxide condensate                                                                          Ethomids                                                 with primary fatty amides                                                 9.  fatty alcohol polyglycolether                                                                      Lorox                                               10.  sorbitolsesquioleate Nonion OP-83                                        11.  polyoxyethylene lauryl ether                                                                       Brij-35                                             12.  polyoxyethylene lauryl alcohol                                                                     Igepal-430                                          13.  polyetherated fatty alcohols                                                                       Emulphor-CN                                                                   Emulphor-CN-870                                     14.  polyoxyethylated octyl phenol                                                                      Triton X-100                                             having 8 to 10 ethylene oxide                                                 units                                                                    ______________________________________                                    

The Polymeric Emulsifiers include the water dispersible polyelectrolytesset forth in Hedrick and Mowry's U.S. Pat. No. 2,625,529 relating to"Methods of Conditioning Soils." In said patent are listed a number ofwater-soluble polyelectrolytes and these materials are defined as"synthetic water soluble polyelectrolytes having a weight averagemolecular weight of at least 10,000 and having a structure derived bythe polymerization of at least one monoolefinic compound through thealiphatic unsaturated group and substantially free of cross-linking."The present invention has shown that these synthetic water solublepolyelectrolytes can be employed as emulsifiers for the preparation oflatices as herein set forth. The disclosed polyelectrolytes of thispatent are therefor incorporated herein by reference, it being notedhowever that the lower limit of molecular weight prescribed by thepatentee does not apply, the applicable criterion being that thematerials are water soluble or water dispersible emulsifiers.

Combinations of emulsifiers. The present invention has disclosed that byusing certain combinations of emulsifiers, it becomes possible toprepare a stable latex from aliphatic hydrocarbon polymers dissolved inhydrocarbon solvents and even in aromatic solvents, as is desirableunder certain processing conditions. An effective emulsifier combinationfor aqueously emulsifying 100 parts by weight of a hydrocarbon rubberdissolved in from about 300 to 600 parts of an aromatic hydrocarbonsolvent such as toluene, may comprise 10 parts by weight of a nonionicemulsifier, e.g. polyoxyethylated octyl phenol such as Triton X-100, atrade mark product and one part by weight of an anionic emulsifier, e.g.sodium lauryl sulfate.

Another effective emulsifier combination for 100 parts by weight ofhydrocarbon rubber dissolved in about 400 parts of aromatic solvent suchas toluene combines 3 parts by weight of the aryl anionic emulsifier,sodium salt of an alkaryl polyether sulfate e.g. Triton W-30 (a trademark product) and 3 parts by weight of the non-aryl anionic emulsifiersodium lauryl sulfate, e.g. Dupanol WAQ (a trade mark product).

It has for some time been a desideratum in the art to have a stablehydrocarbon rubber latex suitable for combination with asphalt orasphalt emulsions, for road surfacing and roofing purposes, for example.Application Ser. No. 691,823 has disclosed that latices of hydrocarbonrubber such as butyl rubber, polyisobutylene, ethylene-propylene rubberor rubbery amorphous polypropylene, which are suitable for such use, canbe prepared by employing as emulsifier for the hydrocarbon solventsolution of the rubber a combination of emulsifiers in which one or morequaternary ammonium emulsifiers (e.g. the quaternary ammonium compoundssupplied under the Redicote trade mark), are combined with one or morefatty acid amine or diamine type emulsifiers in the ratio of quaternaryammonium to fatty acid amine in the range of from 1:5 to 5:1,notwithstanding that the quaternary ammonium emulsifiers alone, for themost part, will not form stable aqueous emulsions with the above typesof hydrocarbon polymers.

For example a stable aqueous latex is obtained from hydrocarbon rubbere.g. butyl rubber or ethylenepropylene rubber, dissolved in an aliphaticor even an aromatic solvent, e.g. hexane, benzene, toluene and/or thezylenes, with the aid of a mixture of the emulsifiers selected fromsubgroups (a) and (b) in the ratio of 0.5:5 to 5:0.5 parts by weight,said mixture being employed in the amount of 2 to 10 parts by weightbased on the polymer, and said sub-groups (a) and (b) being representedby formulae I and II respectively: ##EQU1##

    [R'--NH.sub.2 --(CH.sub.2).sub.3 --NH.sub.3 ].sup.+.sup.+2[X].sup.- II.

wherein R and R' are selected from the alkyl radicals having from 8 to22 carbon atoms and X is an acid anion, preferably the alkyl radicalsbeing those derived from cocoanut oil and/or tallow fatty acids.

The quantity of emulsifier employed in this invention is in the range of2% to 20% by weight and preferably 4% to 12% by weight based on the highpolymer composition; and if desired, small additions of electrolyte maybe made to the latex or in preparing the course or fine emulsion, as,for example, in accordance with the practices referred to in U.S. Pat.Nos. 2,955,094 issued Oct. 4, 1960 and 3,222,311, issued Dec. 4, 1965,to Esso Research and Engineering Company, as assignee of R. S. Brodkeyet al, and A. L. Miller et al. Alkali metal acid phosphate salts aresuitable for this purpose, and are also useful in connection with theuse of the addituent 24d (FIG. 1) as above described, for reducing thequantity of said addituent required.

MONOMER MATERIALS (24b)

The ethylenically unsaturated monomer material employable herein isselected from the class consisting of:

i. the mono-ethylenically unsaturated aromatic hydrocarbon monomerscontaining from 8 to 18 carbon atoms,

ii. the conjugated diene hydrocarbon monomers containing not more than12 carbon atoms,

iii. the non-conjugated diene hydrocarbon monomers containing not morethan 18 carbon atoms,

iv. the mono-ethylenically unsaturated monomers containing polar groupsand having not more than 18 carbon atoms, and

v. the non-conjugated diene and triene monomers containing polar groupsand having not more than 22 carbon atoms,

the polar groups of (iv) and (v) being selected from the classconsisting of carboxyl, hydroxyl, carbonyl, ester, ether, nitrile,amine, quaternary ammonium, amide, triazine, halogen, and sulfur orphosphorous containing groups.

Examples of the respective groups of monomers comprised in the aboveclass are set forth in my aforesaid applications, particularlyapplication Ser. No. 784,596, filed Dec. 18, 1968, and are hereinincorporated by reference.

FREE-RADICAL GENERATING POLYMERIZATION CATALYSTS (24a)

The free-radical generating catalysts and catalyst systems useful in therange of 0.8 to 20 parts per 100 parts of added monomer materialsemployed in certain embodiments of the present invention constitute awell-known class which includes: the inorganic peroxides such ashydrogen peroxide and the like; the various organic peroxy catalysts,such as the dialkyl peroxides, e.g. diethyl peroxide, diisopropylperoxide, dilauryl peroxide, dioleyl peroxide, distearyl peroxide,di-(tertiary-butyl) peroxide; di-(tertiary amyl) peroxide, dicumylperoxide and the like; the alkyl hydrogen peroxides such as tertiarybutyl hydroperoxide, tertiary amyl hydroperoxide, cumene hydroperoxide,tetralin hydroperoxide, and diisopropyl benzene hydroperoxide and thelike; the symmetrical diacyl peroxides, for instance acetyl peroxide,propionyl peroxide, lauroyl peroxide, stearoyl peroxide, malonylperoxide, succinoyl peroxide, phthaloyl peroxide, benzoyl peroxide;ketone peroxide such as methylethyl ketone peroxide, cyclohexanoneperoxide, and the like; the fatty oil acid peroxides, such as cocoanutoil acid peroxides and the like; the unsymmetrical or mixed diacylperoxides, such as acetyl benzoyl peroxide, propionyl benzoyl peroxideand the like; the azo compounds such as 2-azobis (isobutyronitrile),2-azobis (2-methylbutyronitrile), 1-azobis (1-cyclohexancarbonitrile)and the like, and other free radical generating catalysts employable inemulsion polymerization, such as peroxy-catalyst compounds incombination with a reducing compound such as an amine, e.g. triethylenetetramine or tetraethylene pentamine, with or without metallic ioncombination, e.g., ferrous ions, which systems are referred to as"redox" free-radical generating catalyst systems, which latter arefurther exemplified in the treatise "Emulsion Polymerization" by F. A.Bovey, et al, 1955 Interscience Publishers, Inc., New York, N.Y. atpages 71-93, herein incorporated by reference.

CROSS-LINKING AGENTS (24c)

The cross-linking agents useful, in the range of 0.1 to 20 parts per 100parts of polymer content of the latex by weight, for effecting thecross-linking employed in particular embodiments of the presentinvention, also form a well-known class of materials which includes:elemental sulfur, selenium and tellurium, and compounds containing theseelements, usually in their lower valence states or covalance states, andother polyfunctional free radical generating catalysts. Compounds whichliberate sulfur, selenium or tellurium during irradiation or during heataging (100° to 200° C.) are useful. Polymers containing sulfur, seleniumor tellurium and/or monomers capable of forming such polymers are alsouseful. Conventional rubber vulcanizing agents and vulcanizingaccelerators are particularly adapted to this application. Specificcompounds of the class are: The mercapto thiazoles, such as2-mercaptobenzothiozole and its salts, for example its zinc salt,thiuram sulfides, such as tetraethylthiuram monosulfide andtetrabutylthiuram monosulfide; guanidines, thiourea, substitutedthioureas, thiocarbanilides, substituted thiocarbanilides such aso-dimethylthiocarbanilide and its isomers and alkyl homologs; zincdialkyl dithiocarbamates such as zinc dimethyl dithiocarbamate, zincdiethyldithiocarbamate, zinc dibutyl dithiocarbamate, and zinc dibenzyldithiocarbamate or accelerators containing these materials, thiuramssuch as tetramethylthiuram disulfide, tetraethylthiuram disulfide, andother tetra substituted thiuram disulfides; selenium dialkyldithiocarbamates such as selenium diethyldithiocarbamate;2-benzothiazyl-N,N-diethylthiocarbamyl sulfide; sodium or potassiumdimethyldithiocarbamate; xanthates such as dibutyl zanthogen disulfideand Naugatuck Chemical's CPB and ZBX; alkyl phenol sulfides;bis(dimethylthiocarbamyl) disulfide, dipentamethylene tetrasulfide; andsulfur containing polymers such as Thiokol VA-3, 4,4-dithiomorpholineand disulfides such as benzothiazyl disulfide. In fact, any compound inwhich sulfur, selenium or tellurium is attached only to an atom ofcarbon, hydrogen, nitrogen or to another sulfur, selenium or telluriumatom, as the case may be, may be suitable.

Also included in the class are the sulfonyl hydrazides and disulfonylhydrazides. The latter are particularly useful since they contain twowidely separated sulfur-bearing moieties capable of forming sulfurcross-links or free radical derived cross-linkages (as a result ofthermal loss of nitrogen). Blowing agents such as p,p'-oxybis (benzenesulfonyl hydride), p,p'-diphenyl bis(sulfonyl hydrazide) andm-benzene-bis(sulfonyl hydrazide) are examples of additives which canalso be employed as cross-linking agents.

Included in the class are the cross-linking azo compounds, e.g.di-cyano-azo-butane; and the like.

Included in the class are also the peroxy compounds such as bis(α-,α-dimethyl-dicumy) peroxide (dicumyl peroxide), 1,3-bis(α-,t.butylperoxypropyl) benzene, 2,5-bis(t.butylperoxy)-2,5-dimethylhexane,2,5-dimethyl-2,5--di(t.butylperoxy)hexyne-3, di(α-,α-dimethyl-p-chlorobenzyl)peroxide, di(α-,α-dimethyl-2,4-dichlorobenzyl)peroxide, di(α-, α-dimethyl-naphthyl)peroxide and the like.

Further included in the class are combinations of the above said peroxycompounds and the above said sulfur, selenium and tellurium compounds.

BRIEF DESCRIPTION OF THE DRAWING

In the accompanying drawings:

FIG. 1 to 3 are respectively flow sheets or diagrams of the processembracing the present improvements and the process steps and apparatusfeatures which cooperate with said specific improvements and to theembodiment thereof in a complete process and apparatus for producinglatex from an emulsion of solvent polymer cement; FIG. 1 being a flowsheet or diagram illustrating the sequences of steps and flow ofmaterial in the process which incorporates the typical embodiments ofprocess set forth in FIG. 3; FIG. 2 being a diagram of a preferred formof equipment for preparing the latex in which is incorporated theembodiments of the process set forth in FIG. 3; and FIG. 3 being a flowsheet and diagram setting forth the specific process improvements andapparatus features of this invention.

DESCRIPTION OF PREFERRED EMBODIMENTS

a. In General:

The particular improvements hereinafter described in connection withFIG. 3 are applied to overall processes and apparatus for producinglatices, as illustrated in FIGS. 1 and 2, and are particularlycooperative with preferred embodiments thereof.

In such preferred embodiments as illustrated in FIG. 1, the high polymer1, e.g. elastomer and/or plastomer material and/or resins or resinousmaterial with or without compounding ingredients as hereinafterdescribed, is prepared as a high polymer composition 4 for conversion toa cement, as by working in appropriate masticating, comminuting, orattenuating equipment 2 such as a rubber mill, Banbury comminutor,extruder, or the like. In accordance with the aforesaid applicationsprovision may be made for incorporating one or more known polymercompounding ingredients 3, e.g. rubber reinforcing filler, into the saidpolymer composition in such a way that the ingredients 3 are thereaftercontained within the polymer particles of the latex being formed, forwhich purpose the said ingredient or ingredients 3 may be worked intothe high polymer 1 by working therewith in the masticating equipment 2.By such procedure the said polymer ingredients may become fixed to thecompounding ingredient, i.e. the polymer particles can become reinforcedby the fillers, and in effect become so intimately attached thereto, orembrasive thereof, as to retain the same when dispersed as a cement. Inthe case of compounding imgredients desired to be incorporated in thelatex particles, but not requiring working with the polymer itself, suchingredients 3 may be fed into the cement forming equipment or dissolver5 independently of the said polymer composition 4, as is also indicatedin FIG. 1.

In the cement forming equipment or mixer of dissolver 5 which may alsocomprise a disperser, the high polymer composition 4 is combined andpreferably stirred or otherwise worked with solvent 6 appropriate forthe high polymer and for the process, as further described herein, toform a solvent cement 7 of the high polymer composition 4 and of anyextraneously added compounding ingredients 3, the adequate dispersion ofwhich in the cement may require virorous working, which may even beaccomplished by the passage of the cement through a suitable dispersingequipment 7a.

The solvent/polymer cement 7 is then combined with emulsifier 8appropriate for the high polymer and the process, and with water 9 in acoarse emulsion mixing equipment 10 where the ingredients are mixed,preferably with the aid of heat, to form a coarse cement in wateremulsion 11, which is then passed one or more times through anultradispersing equipment 12, which breaks up the relatively largeparticles of solvent-cement forming the discontinuous phase in thecoarse emulsion 11 into particles principally of precursor latex size,i.e. which will be of latex particle size when relieved of their solventcontent, and preferably in the upper portion of the colloidal sizerange.

As in my aforesaid applications the coarse cement-in-water- emulsion 11may be passed one or more times, usually 6 to 12 times, through one ormore so-called ultradispersers 12 e.g. of the "Moulds" or "Hager" typedescribed in U.S. Pat. No. 3,195,867 and in U.S. Pat. No. 3,194,540, inorder to accomplish a sufficient reduction of latex particle size. Theresulting fine emulsions have rather wide ranges of cement droplet sizedistribution and, adjusted if necessary to an appropriate temperature,as by the cooler 13A, by-pass 13B and/or heater 13C, may be fed bysuitable positive displacement, e.g. plunger, pump means 13D, to ahomogenizer (13E), preferably of the vibrating blade type e.g. theRapisonic (trademark) liquid whistle operating at 300 to 500 p.s.i.inlet and 30 to 50 p.s.i. outlet or of the resiliently restrictedorifice type high pressure homogenizer operating at pressures in therange of 1,000 to 10,000 p.s.i., e.g. the "Gaulin" type, see U.S. Pat.No. 753,792 and 756,953, for reducing the particle size distribution ofthe fine emulsion. The resulting emulsion 13 of reduced particle sizedistribution with or without cooling by a cooler 13F is preferablydelivered directly to a steam mixer or aerosol generator 14 where it isdispersed into a flow of gas comprising steam. As indicated in FIG. 1the emulsifier material 8 may be formed into an aqueous emulsifiersolution 8' with water 9' saturated with solvent or with water 9" froman extraneous source.

The resulting fine cement-in-water emulsion 13, in accordance with myaforesaid applications may be an unstable emulsion of only temporarilyprecursor latex size particles, and may be either stabilized as byadding further emulsifier or may be immediately converted into anaerosol, of which the dispersed phase may comprise colloidal and largersized droplets in a steam/solvent vapor continuum, thus minimizingagglomoration of polymer-solvent particles into greater than precursorlatex particle size, and is therein stripped of its solvent content. Insuch aerosol form the stripping is accomplished without excessivefoaming and while avoiding or minimizing formation of coagulum,desiderata which cannot be attained when any substantial proportion ofsolvent is attempted to be removed from an aqueous emulsion of highpolymer solvent cement in other than an aerosol condition. As in theaforesaid applications, the formation of the aerosol is preferablyaccomplished by providing a flow of gas comprising steam 14a as aninitial continuous phase and introducing the aqueous emulsion of atleast temporarily precursor latex sized particles 13 as a discontinuousphase into the flow of steam as the initial continuous phase in a mixeror aerosol generator 14, whereby volatile solvent 6 is vaporized tobecome the continuous phase or the principal part thereof, and acorresponding amount of steam is condensed to supply the heat ofvaporization for the solvent and become added as water to thediscontinuous phse or to be used in accordance with this improvement forthe supply of the gas comprising steam as set out in more detailhereinafter in connection with FIG. 3.

The final separation or collection may be achieved by delivering theflows from the segregator 15 into a separator or collector 16, from thelower part of which the latex is drawn, and from an upper part of whichthe continuous vapor phase is passed to condensing equipment 17maintained under reduced pressure, preferably a vacuum of the order of28 to 29 inches of mercury by withdrawal of uncondensed gases therefromby vacuum pumping equipment 18. The gases are condensed in condenser 17and the solvent with its dissolved water is separated and sent tostorage 22 and recirculated to the process storage 6 while thesolvent-containing water, which may be saturated with solvent, is sentto storage 23 and can provide at least a part of the water for thecoarse emulsion mixer 10 through water storage 9.

Still referring to FIG. 1, the high polymer composition latex 19withdrawn from the separator 16 may be in part delivered as product 24,and is recycled as indicated at 21, that is it may be cycled through adifferent or the same heater and separator (21 and 16) for concentratingthe latex, in which event the latex is heated to evaporate watertherefrom under sub-atmospheric pressure at temperatures within thelimited temperature range for its stability and said evaporated watervapor is removed (as by lines 24OD' and/or line 24OD" FIG. 2) andcontinuing with FIG. 1, condensed and returned to water storage as at 23and 9 and may be employed to prepare emulsion as at 10 and/or, inaccordance with the present improvements, to provide the gas comprisingsteam at 14a as in more detail set forth in FIG. 3.

As in my U.S. application Ser. No. 784,596, various provisions may beemployed for modifying the latex 24. These provisions are illustrated at24 and following in FIG. 1 herein. Thus, in these embodiments of theprocess, the latex of intermediate solids content may be mixed in a holdtank, mixer, or proportionate feeder 24 with polymerization catalyst 24aand monomer material 24b, and after appropriate adjustment of itstemperature, as by a heat exchanger means 25, may be passed topolymerization reactor means 27. The modified polymer latex delivered bythe reactor with or without added emulsifier 8A may be delivered tostorage 29, preferably through a cooler 28, pending delivery as by apump 30 for further treatment in heating and separating apparatus 31 and32. In this further treatment residual solvent, odors, and unreactedmonomers, if any, may be removed, and if desired the latex may befurther concentrated. The modified latex from separator 32 which in eachevent will have, along with other modifications, a higher solids contentthan the latex 24, may be passed by a pump 34 to product storage 36,preferably through a cooler 35.

In certain embodiments of the process, the operations up to point 24 maybe conducted to form latex of low molecular weight polymer, whichenables a latex of higher solids content to be employed without havingto deal with excessively high viscosity, and monomer 24b and catalyst24a, and temperature in the apparatus 27 may be employed in suchquantities and degree as to materially augment the molecular weight ofthe polymer, and especially when it is desired to highly augment suchmolecular weight, polymer cross-linking agent 24c may be added in themixer 24, for intimate association and reaction in the apparatus (27).

The final stripping, deodorizing, and/or concentrating in separator 32is preferably effected as shown with the aid of condensing equipment 37and vacuum pumping apparatus 38, and when such equipment produces ayield of recoverable fluid, e.g. water, such may be returned for reuse,e.g. to the water supply 23, or to water supply 9 as shown. Whereprolonged shelf life is desired, additional emulsifier may be added tothe latex from 8A, preferably ahead of the pump 34'.

FIG. 2 illustrates diagrammatically suitable apparatus to carry out theprocess to which the features of the inventions are applied. In thisarrangement the separators 216', 216", and 240" may be of any suitabletype. Separator 216' comprises a first tangential inlet for latex,solvent vapor and steam 215H, a flow restricting means or valve 215H' toregulate the back pressure, and second tangential inlet means 222A'and/or 222B' for flow of latex from heat exchangers (preferably plateheat exchangers) 220A' and 220B' with flow restricting means or valves;said streams of latex from recirculating and/or latex concentratingcircuit as illustrated at 216I' to 221A' and 216I' to 221B" and/or latexfrom any other source or latex of a different polymer composition thanthat carried by the stream 215H, when a mixture of latices is to beproduced. In FIG. 2 the aqueous emulsion of precursor latex sizedsolvent/polymer material is delivered through pipe 114E' tostripper-mixer 114' together with steam supplied through valved line114L' (generated from the aqueous phase condensate of vapor removedthrough lines 240D' and/or 240D" is hereinafter set out in connectionwith FIG. 3.) with or without steam supplied through valved line 114D'and the resulting aerosol is conveyed through conduit section 215H withthe pressure therein being regulated by the flow restricting means orvalve 215H'. The aerosol of latex and solvent vapor, with or withoutexcess steam, is delivered tangentially into separator 216' whichoperates at a lower pressure than the pressure within the mixer-stripper114'.

Aqueous emulsion of solvent/polymer cement can be prepared with anemulsifier content which is not sufficient to permit stripping with theaid of steam without formation of an appreciable quantity of polymercoagulum; however, by blending the said emulsion with stripped latexfrom which solvent and water have been removed without substantialremoval of emulsifier, the emulsifier content in the aqueous phase ofthe blend can be made sufficient to permit stripping without appreciableformation of coagulum. This provision of the present process isillustrated in one embodiment in FIG. 2, wherein pre-mixer 114M issupplied with an aqueous emulsion of solvent polymer cement throughconduit 114E' and stripped polymer latex through conduit 114L, thisstripped latex being recycled from a location downstream of the stripper114' with the aid of pump 114P to pre-mixer 114M; the latex/emulsionblend flowing to mixer-stripper 114' and through conduit 215H and valve215H' to separator 216'.

Pump 114P may draw the recycled latex from the separator 216' via line115 and by opening valve 115V, but preferably draws more concentratedlatex from a more downstream separator 216" via line 115' by openingvalve 115V' or via line 240H"' as by opening valve 120. Less desireablythe pump 114P may draw latex of augmented particle size by opening valve117, or even of reduced emulsifier content or both reduced emulsifiercontent and augmented particle size by opening valve 119.

In the form shown in FIG. 2 the skirt in separator 216' takes the formof a cylindrical wall generally concentric with and preferably in fairlyclosely spaced relation to the surrounding wall of the separator todefine a relatively narrow annular space extending completely around theseparator, closed at its top and open at its bottom, into which theflows of aerosol and latex are delivered to cause the aerosol dropletsto impinge on the latex flowing helically, peripherally and downwardlyinside the confining wall. In this arrangement a multiplicity oftangential inlets alternately for latex and for aerosol may readily beaccommodated, it being understood that the latex will be deliveredthereby so as to be impinged upon by the aerosol in any sucharrangements or vice versa. The vapor outlet from thesegregator-collector 216' delivers to the tangential inlet of a secondcollector 240', operated at a lower pressure than separator 216' and anon-condensing temperature for the solvent and its aqueous azeotrope,which entraps any minor quantity of latex droplets and/or foam that maybe carried thereinto via 216D', and conduit 240D' carries away thegaseous vapors to the condensing system and recycling system set forthin FIG. 3. In FIG. 2 the latex separated in 216' with the aid of pump216C' may in part be discharged through valve 246H, but preferably saidlatex is pumped via line 216F' alternately through filters 230A' and230B' before further concentration or withdrawal. For partialconcentration and for forming the flow of latex in 216', the filteredlatex is delivered via conduit 216J' alternately or concurrently throughheat exchangers 220A' and 220B' delivering tangentially into separator216' via lines and valves 221A' and 221B', and when said valves aresufficiently open boiling takes place in the heat exchanger 220A' and220B', however, the preferred embodiment is to partially close thevalves until no boiling occurs in heat exchangers 220A' and 220B'.

To avoid flooding separator 216' an amount of latex equal to thatentering the separator through line 125H must be removed, via conduit246H' and/or conduit 216K. The partially concentrated latex removed viaconduit 216K is pumped via pump 240D" with the aid of three-way valves240E' and 240E" to surge tank 240E and therefrom to conduit 216F" withthe aid of pump 240E"' (or alternately, the surge tank may be bypassedvia line 216K" ) and thence through alternate filters 230 " and 230B"and through conduit 216J" alternately or concurrently through heatexchangers 220A"; and 220B" and tangentially into concentrator 216".Valves 221A" and 221B" when sufficiently open permit heat exchangers220A and 220B" to be operated so that boiling takes place within theheat exchangers, however, in the preferred manner of operating thevalves 221A" and 221B" are partially closed until no boiling of theaqueous phase of the latex occurs in heat exchangers 220A" and 220B". Toinhibit carryover or entrainment of latex particles and/or foam to thevapor recovery system, separator 240" is interposed between conduits216D" and 240D" and this separator functions similarly to separator 240'which is interposed between conduits 216D' and 240D' and any carriedover latex which is thrown down by separator 240" is discharged from thebottom of the separator and pumped by pump 240C" into recycle conduit216J;; and in a like manner separator 240' discharges with the aid ofpump 240C' into recycle conduit 216J'. The gaseous vapors fromseparators 216" and 240" are circulated via line 240D" to the condensingand steam generating recycle system set forth in FIG. 3.

The partially concentrated and filtered latex product may be removed viaconduit 240H' and/or product after final concentration may be removedthrough conduit 240H" by opening valve 240K" or after filtering throughconduit 240H"' with the aid of pump 240P.

If it should be desired to alter the viscosity of all or part of thelatex product, this may be accomplished by passing all or part of thelatex delivered by pump 240P via valve 2413V to viscosity altering meansbetween the valves 2413V, 250V, 231V and 116V.

In the form shown in FIG. 2, to provide altered particle size latex asupply of latex from pump 240P or from valve 231V is passed through line2413L to the size altering means 2413. The latex product of alteredparticle size may be delivered through line 2413L' and Valves 116V and116B' as latex product.

To provide latex of decreased emulsifier content, a supply of latex ispassed through line 250L and flows through centrifuge 250 (e.g., DeLavalModel No. 244), a trademark product). In order to centrifuge the latexthe dry solids content by weight of such latex must be reduced to therange of 20-40% by addition of water by opening valve 250W. Theoperation of the centrifuge is controlled by controlling serum take-offby adjusting valve 250V' and latex product valve 252V' to provide thelatex product desired which may be delivered through line 252.

An alternate supply of lower solids latex from an earlier stage in theprocess with or without further water dilution, may be fed to thecentrifuge via line 114L' by adjusting valves 114V, 114V' and 231V'. Ina preferred operation the centrifuge is supplied with dilute latex,requiring little or no water addition, via valves 114V and 231V".

Latex of both reduced emulsifier content and increased particle size canbe produced by opening valve 252V and permitting the centrifuged latexto flow through line 2413L" and 2413L to equipment 2413.

Alternatively latex from the so exemplified equipment may be supplied byline 2413L' and by controlling valve 231V is supplied to centrifuge 250and the latex delivered through line 252.

The serum removed via valve 250V', principally water containingemulsifier, may be recycled to the water supplies 9 or 9' (FIG. 1)hereinabove described.

Further encompassed within the scope of the process described by FIG. 2is the use of two or more centrifuges connected in series with serumremoval and water addition between centrifugation steps. Alternativelythe latex may be passed through the centrifuge two or more times withwater dilution of the latex between the centrifugation steps via recyclevalve 224' to mixer 250M' supplied with water from valve 250W.

Aqueous emulsion of solvent/polymer cement can be prepared with anemulsifier content which is not sufficient to permit stripping with theaid of steam without formation of an appreciable quantity of polymercoagulum; however, by blending the said emulsion with stripped latexfrom which solvent and water have been removed without substantialremoval of emulsifier, the emulsifier content in the aqueous phase ofthe blend can be made sufficient to permit stripping without appreciableformation of coagulum. This provision of the present process isillustrated in FIG. 2, wherein pre-mixer 114mo is supplied with anaqueous emulsion of solvent polymer cement through conduit 114E' andstripped polymer latex through conduit 114L, this stripped latex beingrecycled from a location downstream of the stripper 114' with the aid ofpump 114P to pre-mixer 114M; the latex/emulsion blend flowing tomixer-stripper 114' and through conduit 215H and valve 215H' toseparator 216".

Pump 114P may draw the recycled latex from the separator 216' via line115 and by opening valve 115V, but preferably draws more concentratedlatex from a more downstream separator 216" via line 115' by openingvalve 115V' or via line 240H"' as by opening valve 120. Less desireablythe pump 114P may draw latex of augmented particle size by opening valve117, or even of reduced emulsifier content or both reduced emulsifiercontent and augmented particle size by opening valve 119.

The improvements of the present invention are illustrated in oneembodiment in FIG. 3. The aqueous emulsion of solvent-polymer cement isconducted to the aerosol generator 314 and blended with sufficient steamsupplied through conduit 314L with or without auxiliary steam suppliedthrough valve 314M and said steam being in an amount to essentiallyevaporate all of the solvent from the emulsified polymer-solvent cement.The aerosol of latex particles in solvent vapor and water vapor isconducted through conduit 315 and through valve 315V to separator 316.In the separator the solvent vapor and water vapor therewith isseparated from the latex particles. The latex particles are removed asliquid latex from the bottom of the separator with the aid of a conduitand pump 316P. The vapors leaving the separator comprise solvent vaporand water vapor and are conducted through conduit 317L. The water cooledand/or refrigerated condenser 317 or condensers condenses the solventvapor to liquid solvent and the water vapor to liquid water which isthen pumped alternately with the aid of pump 317P to settling tanks 320and 321. When one of the tanks is filled with liquid then the solventand water are permitted to separate while the alternate tank is beingfilled. By the use of three-way valves 320V and 321V and with the aid ofpump 320P the solvent layer saturated with water in each settling tankis pumped to solvent storage tank 322 and the water layer saturated withsolvent is pumped to water storage tank 323. The purpose of collectingthe water saturated with solvent in tank 323 is to permit it to bevaporized and fed as gas comprising steam through conduit 314L toaerosol generator 314. Thus the water saturated with solvent by openingthe three-way valve 323V and 340V passes through conduit 323L to afilter 340. When filter 340 needs to be cleaned then valve 340V isclosed and valve 341V is opened and filter 341 is used to remove anylatex coagulum or other residue which may be in the water saturated withsolvent. Depending on the filter being used valve 340V' or 341V" isopened in order to feed the positive displacement pump 346P. This pump346P pumps the water saturated with solvent to the steam generator 342or 343 at rate controlled with the aid of a thermal probe 346C inaerosol generator 314 connected to the pump motor controller throughelectrical conduit means 346L. Three-way valves 342V' and 343V' permitthe heat exchanger e.g., the plate packages to be used alternately. Byadjusting valve 344 or 345 the steam to the multiple plate package heatexchanger 342 or 343 may be controlled so as to provide the desiredquantity and temperature of the vapor comprising essentially steamrequired by the aerosol generator 314. The quantity of steam required toremove the solvent from the aqueous emulsion of solvent polymer cementmay be controlled by the temperature probe 346C in the mixer 314 whichis connected to pump 346P.

Should the water saturated with solvent in addition to any possiblepolymer coagulant contain any latex then this should separate out ascoagulum in the plate package steam generator. When the plate packagesteam generators become fouled with polymer and are no longer efficientone or the other may be taken out of service by the use of three-wayvalve 342V or 343V and 342V' or 343V' which permits solvent to becirculated through these plate packages. Thus by opening valve 322V',322V" and closing 322VV' and with the aid of pumps 322P and 322P' thesolvent can be conducted through conduit 322L' and 322L" to either ofplate packages 342 or 343 by opening valves 342V or 343V. With the aidof valve 342V' said solvent may be circulated through either platepackage 342 or 343 by a conduit 322L", 322L, and 322L' back to the platepackages 342 or 343 with the aid of pump 322P'. Thus by use of thesolvent recovered from separator 316, the plate packages 342 and 343 canbe kept clean and such plate packages can be used to generate the steamfrom the water saturated with solvent vapor which has been recoveredfrom separator 316. If it is desireable to water wash plate package 342and/or 343 the water saturated with solvent from tank 323 via line andvalve 309 can be circulated via conduit 322L' and pump 322P to platepackages 342 and 343 and by conduit 322L" and three-way valve 322VVreturning to tank 323. Even fresh water may be injected into the cyclefrom line 323M with the aid of pump 346P or from line 323N. Theimprovement thus provides a means for complete re-cycle of solvent andwater within the process, and greatly reduces the amount of waterrequired to be supplied to the process, and can even eliminate dischargeof waste water from the process and contamination of the environmentthereby.

In effect, for vaporization of solvent saturated water, either steamgenerator 342 and 343 may be selectively connected to receive from pump356P water and/or water containing solvent, to vaporize the same, anddeliver therefrom gas comprising steam via line 314L. For solventwashing, either generator may be selectively connected in the loopcircuit 322L', 322P', 322L", 322L, and the said circuit may selectivelybe filled with either solvent from 322 via 322V", or with solventexternally supplied via 322VV', and after soaking, with or withoutheating and/or circulation by operation of pump 322P' in eitherdirection, the solvent may be pumped from the said circuit into tank 322or out through 322VV', as desired. And for water washing, eithergenerator may be selectively connected in the said loop circuit, whichmay be filled with water saturated with solvent from 323 which can bereturned to source 323 when the water washing is concluded. Finally, ifit is desired to use solvent to dissolve polymer deposit from thefilters 340 and/or 341, solvent from 322 via line and three-way valves323V may be fed to the filters, and be pumped therefrom by pump 346P,three-way valve 342V' or 343V' and line 322L" for delivery therefrom.Since solvent and water are continuously fed as emulsified cement toseparator 314, it is desirable that solvent and water in appropriatequantity be continuously withdrawn at 322VV' and 323N.

If it is desired to exclude the filters from the system, this may beaccomplished by setting three-way valves 340V, 341V, to prevent flowthrough the filters and direct the flow through the filter by-pass line.

If it is desired to use the pump 320P in lieu of the pump 346P, this maybe accomplished by turning the three-way valve 322V to deliver to theintake side of pump 320P, and opening the three-way valve 341V' toby-pass the pump 346P.

While there have been described herein what are at present consideredpreferred embodiments of the invention, it will be obvious to thoseskilled in the art that modifications and changes may be made withoutdeparting from the essence of the invention. It is therefore to beunderstood that the exemplary embodiments are illustrative and notrestrictive of the invention, the scope of which is defined in theappended claims, and that all modifications that come within the meaningand range of equivalency of the claims are intended to be includedtherein.

I claim:
 1. In the formation of a latex from an organic solventdispersion of a composition of an organic solvent soluble ordispersible, water insoluble, macromolecular polymer or resin by aprocess of the type which comprises:1. providing a dispersion of thesaid composition in essentially water-immiscible volatile physicalsolvent which itself or as an azeotrope with water has a boiling pointlower than that of water at atmospheric pressure,
 2. adding water andemulsifier to said dispersion in proportions to form an emulsion havingwater as its continuum and emulsifying the same so that thediscontinuous phase thereof is in particles at least principally ofprecursor latex particle size,
 3. stripping the solvent from theemulsion to form a latex, and
 4. recovering the latex product, and whichcomprises the particular steps of:
 5. providing a moving flow of gascomprising steam as an initial continuous phase,
 6. dispersing the saidemulsion into the flow of gas comprising steam as the initial continuousphase while subjecting the phases to a decrease of pressure andmaintaining the temperature thereof below the limiting temperature forstability of the emulsion of particles of precursor latex particle size,thereby vaporizing solvent from the dispersed droplets and forming latexand vapors,
 7. establishing a separating zone maintained at a lowerpressure, and establishing a flow of latex and water vapor into saidseparating zone,
 8. introducing into said separating zone the latexdroplets and vapor produced by step (6) and impinging said droplets uponthe flow of latex therein,
 9. withdrawing from said separating zonevapors therein resulting from steps 7 and 8, and
 10. withdrawing latexfrom said separating zone, the improvement which consists in thecombination in the process of the further steps of:
 11. cooling andcondensing the vapors withdrawn in step (9) to form a mixture of (a)said solvent in liquid form and (b) water containing some solvent, 12.effecting separation of the liquid solvent (a) from saidsolvent-containing water (b),
 13. vaporizing a quantity of saidsolvent-containing water (b) sufficient to form at least a substantialpart of the flow of gas comprising steam required by step (5), and 14.providing the flow of gas in step (5) at least in substantial part fromthe flow of gas formed in step (13).
 2. The improved process as claimedin claim 1, in which step (13) is effected in a vaporizer in which theremay accumulate any of said macromolecular polymer or resin which may beentrained in the vapors withdrawn in step (9), and the improvementfurther comprises the steps of15. isolating said vaporizer from theprocess from time to time, and
 16. removing from said isolated vaporizerany macromolecular polymer or resin accumulated therein by circulatingtherethrough liquid solvent separated in step (12).
 3. The improvedprocess as claimed in claim 1, in which step (13) is effectedselectively in one of two vaporizers in which there may accumulate anyof said macromolecular polymer or resin which may be entrained in thevapors withdrawn in step (9), and the improvement further comprises thesteps of15. from time to time using alternately the respective ones ofsaid vaporizers in step (13) while isolating from the process thevaporizer not being so used, and
 16. circulating through the isolatedvaporizer liquid solvent separated in step (12) for removing therefromany macromolecular polymer or resin accumulated therein.
 4. The improvedprocess as claimed in claim 1, in which15. the latex withdrawn in step(10) is concentrated by vaporization of water therefrom, and the sovaporized water is at least in part combined with the vapors withdrawnin step (9).
 5. The improved process as claimed in claim 1, in which15.the latex withdrawn in step (10) is concentrated by vaporization ofwater therefrom, and the so vaporized water is at least in partcondensed and combined with the solvent-containing water (b) separatedin step (12).
 6. In the formation of a latex from an organic solventdispersion of a composition of an organic solvent soluble ordispersible, water insoluble, macromolecular polymer or resin by aprocess of the type which comprises1. providing a dispersion of the saidcomposition in essentially water-immiscible volatile physical solventwhich itself or as an azeotrope with water has a boiling point lowerthan that of water at atmospheric pressure,
 2. adding water andemulsifier to said dispersion in proportions to form an emulsion havingwater as its continuum and emulsifying the same so that thediscontinuous phase thereof is in particles at least principally ofprecursor latex particle size,
 3. stripping the solvent from theemulsion to form a latex, and
 4. recovering the latex product, and whichcomprises the particular steps of:
 5. providing a moving flow of gascomprising steam as an initial continuous phase,6. dispersing the saidemulsion into the flow of gas comprising steam as the initial continuousphase while subjecting the phases to a decrease of pressure andmaintaining a temperature for stability of the emulsion of particles ofprecursor latex particle size, thereby vaporizing solvent from thedispersed droplets and forming latex and vapors,
 7. establishing aseparating zone maintained at a lower pressure,
 8. introducing into saidseparating zone the latex droplets and vapors produced by step (6), 9.withdrawing vapors from said separating zone, and
 10. withdrawing latexfrom said separating zone,the improvement which consists in thecombination in the process of the further steps of:
 11. cooling andcondensing the vapors withdrawn in step (9) to form a mixture of (a)said solvent in liquid form and (b) water containing some solvent, 12.effecting separation of the liquid solvent (a) from saidsolvent-containing water (b).13. vaporizing a quantity of saidsolvent-containing water (b) sufficient to form at least a substantialpart of the gas required by step (5), and
 14. providing the flow of gasin step (5) at least in substantial part from the flow of gas formed instep (13).
 7. The improved process as claimed in claim 6, in which step(13) is effected in a vaporizer in which there may accumulate any ofsaid macromolecular polymer or resin which may be entrained in thevapors withdrawn in step (9), and the improvement further comprises thesteps of15. isolating said vaporizer from the process from time to time,and
 16. removing from said isolated vaporizer any macromolecular polymeror resin accumulated therein by circulating therethrough liquid solventseparated in step (12).
 8. The improved process as claimed in claim 6,in which step (13) is effected selectively in one of two vaporizers inwhich there may accumulate any of said macromolecular polymer or resinwhich may be entrained in the vapors withdrawn in step (9) and theimprovement further comprises the steps of15. from time to time usingalternately the respective ones of said vaporizers in step (13) whileisolating from the process the vaporizer not being so used, and 16.circulating through the isolated vaporizer liquid solvent separated instep (12) for removing therefrom any macromolecular polymer or resinaccumulated therein.
 9. The improved process as claimed in claim 6, inwhich15. the latex withdrawn in step (10) is concentrated byvaporization of water therefrom, and the so vaporized water is at leastin part combined with the vapors withdrawn in step (9).
 10. The improvedprocess as claimed in claim 6, in which15. the latex withdrawn in step(10) is concentrated by vaporization of water therefrom and the sovaporized water is at least in part condensed and combined with saidsolvent-containing water (b) separated in step (12).
 11. The improvedprocess as claimed in claim 6, in which the improvement furthercomprises the step that15. between steps (12) and (13) thesolvent-containing water (b) to be vaporized in step (b) is filteredbefore said vaporization.
 12. The improved process as claimed in claim11, in which step (15) is affected in a filter in which there may beaccumulated macromolecular polymer or resin which may be entrained inthe vapors withdrawn in step (9), and the improvement further comprisesthe steps of16. isolating said filter from the process from time totime, and
 17. removing from said isolated filter any macromolecularpolymer or resin accumulated therein by circulating therethrough liquidsolvent separated in step (12).
 13. The improved process as claimed inclaim 12, which further comprises the step of18. delivering the solventeffluent from step (17) with any macromolecular polymer or resindissolved therein to step (1) for forming the dispersion therein.